US4614671A - Artificial leather with non-woven or fluffy cloth base and foamed PVC filler - Google Patents
Artificial leather with non-woven or fluffy cloth base and foamed PVC filler Download PDFInfo
- Publication number
- US4614671A US4614671A US06/555,706 US55570683A US4614671A US 4614671 A US4614671 A US 4614671A US 55570683 A US55570683 A US 55570683A US 4614671 A US4614671 A US 4614671A
- Authority
- US
- United States
- Prior art keywords
- artificial leather
- woven
- paste
- mat
- machine
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/007—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by mechanical or physical treatments
- D06N3/0072—Slicing; Manufacturing two webs at one time
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06N3/06—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with polyvinylchloride or its copolymerisation products
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S428/00—Stock material or miscellaneous articles
- Y10S428/904—Artificial leather
Definitions
- the present invention relates to artificial leather and more particularly to an artificial leather with non-woven mat or fluffy cloth base and foamed PVC filler.
- the product is a laminate of non-woven or fluffy cloth and a structure of foamed PVC.
- Non-woven cloth in the market is usually a non-woven mat impregnated with paste of NBR or SBR.
- the cost is quite high.
- Artificial leather with such cloth as base is made by adhering PVC or PU thereto, but both hand feeling and physical properties are not good. The reasons are: so far as the non-woven cloth is concerned,
- the non-woven mat is merely a fiber filled material, with insufficient strength, too easily to be deformed under stretching.
- the main object of the present invention is to provide a laminate of PVC foamed structure with non-woven mat or fluffy cloth, to improve the physical properties and hand feeling of the finished artificial leather which is suitable for many uses.
- Another object of the present invention is to provide an artificial leather of light weight per unit which is required in the manufacture of sport shoes and luggage.
- a further object of the present invention is to provide an artificial leather with a laminate structure of non-woven mat or fluffy cloth base with foamed PVC filler, the base material therein is of non-direction or random orientation to facilitate sampling and cutting with the least waste possible.
- Still another object of the present invention is to provide a base material when PVC sheet or PU is to be applied or coated thereon, the adhesion can be directly effected without further pasting procedure to achieve better appearance.
- a still further object of the present invention is to provide a novel artificial leather with non-woven mat or fluffy cloth base and foamed PVC filler, that is of low cost and easy to be manufactured in mass production.
- FIG. 1 is a schematic diagram of the structure of non-woven material of the prior art which is a non-woven mat (11') impregnated with rubber paste agent (12').
- FIG. 2 is a schematic diagram of a structure of conventional artificial leather (10') composed of from top to bottom the successive layers of a PVC sheet (3), a foamed PVC layer (2) and a base cloth (1);
- FIG. 3 illustrates the structure of an embodiment of the artificial leather of the present invention, wherein PVC resin or foamed PVC (12) is filled to form non-woven mat or fluffy cloth (11) based artificial leather (10); and
- FIG. 4 shows another embodiment of the artificial leather of the present invention which is formed with PVC sheet or PU (20) adhered to a non-woven cloth or fluffy sheet (10) which is filled with PVC resin or foamed PVC (12).
- a formulation of the impregnating plastic paste, foamable or non-foamable is as follows:
- Staples of synthetic fiber are beaten and mixed
- mat material thus formed is of non-direction or random oriented.
- First beat and mix the synthetic fiber staples then feed into a combing machine, set the fibers into lateral netting then into longitudinal netting by needle to foam non-woven mat.
- the impregnated base mat is squeezed and pressed flat to retain 0.5-2.5 Kg/Yd.-38" of plastic paste and then dried at 140°-180° C. prior to further processing.
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
- Laminated Bodies (AREA)
Abstract
Artificial leather having a novel structure comprises a non-woven cloth mat or fluffy cloth as the base, while the structure is filled with foamed PVC. The product thus formed is of excellent physical property, resilience and hand feeling.
Description
The present invention relates to artificial leather and more particularly to an artificial leather with non-woven mat or fluffy cloth base and foamed PVC filler. In other words, the product is a laminate of non-woven or fluffy cloth and a structure of foamed PVC.
Existing non-woven cloth in the market is usually a non-woven mat impregnated with paste of NBR or SBR. The cost is quite high. Artificial leather with such cloth as base is made by adhering PVC or PU thereto, but both hand feeling and physical properties are not good. The reasons are: so far as the non-woven cloth is concerned,
(i) The non-woven mat is merely a fiber filled material, with insufficient strength, too easily to be deformed under stretching.
(ii) The impregnated with NBR or SBR fails not only to give resilient feel and porosity but also causes a phenomenon of so called "orange skin effect", so that the value of the product is degraded;
(iii) Consumers reject the product because of its uncompetitive property and high price.
Hence the artificial leather there-produced inherits the undesirable quality and becomes,
(i) either too stiff or too soft, hand feeling is poor;
(ii) lack of good appearance;
(iii) general deficiency in property is the cause of poor durability and liable to damage after use.
In view of such draw-backs of the conventional non-woven cloth and the structure of artificial leather so made, a novel artificial leather with improved structure results from the diligent study of the present inventor.
Therefore, the main object of the present invention is to provide a laminate of PVC foamed structure with non-woven mat or fluffy cloth, to improve the physical properties and hand feeling of the finished artificial leather which is suitable for many uses.
Another object of the present invention is to provide an artificial leather of light weight per unit which is required in the manufacture of sport shoes and luggage.
A further object of the present invention is to provide an artificial leather with a laminate structure of non-woven mat or fluffy cloth base with foamed PVC filler, the base material therein is of non-direction or random orientation to facilitate sampling and cutting with the least waste possible.
Still another object of the present invention is to provide a base material when PVC sheet or PU is to be applied or coated thereon, the adhesion can be directly effected without further pasting procedure to achieve better appearance.
A still further object of the present invention is to provide a novel artificial leather with non-woven mat or fluffy cloth base and foamed PVC filler, that is of low cost and easy to be manufactured in mass production.
In conjunction with the annexed drawings, the present invention is described by way of examples and embodiments in more details, where:
FIG. 1 is a schematic diagram of the structure of non-woven material of the prior art which is a non-woven mat (11') impregnated with rubber paste agent (12').
FIG. 2 is a schematic diagram of a structure of conventional artificial leather (10') composed of from top to bottom the successive layers of a PVC sheet (3), a foamed PVC layer (2) and a base cloth (1);
FIG. 3 illustrates the structure of an embodiment of the artificial leather of the present invention, wherein PVC resin or foamed PVC (12) is filled to form non-woven mat or fluffy cloth (11) based artificial leather (10); and
FIG. 4 shows another embodiment of the artificial leather of the present invention which is formed with PVC sheet or PU (20) adhered to a non-woven cloth or fluffy sheet (10) which is filled with PVC resin or foamed PVC (12).
A formulation of the impregnating plastic paste, foamable or non-foamable, is as follows:
______________________________________ Ingredient Parts by weight ______________________________________ PVC emulsion Powder 100 plasticizer 30-140 filler, CaCO.sub.3 0-100 foaming agent 0-4 stabilizer 2-5 diluent, white alcohol 5-30 pigment 0-10 ______________________________________
Now the manufacturing Processes are described stepwise:
(A) Preparation of non-woven mat:
1. Staples of synthetic fiber are beaten and mixed;
2. comb or needle comb;
3. net setting first laterally then longitudinally by needle;
mat material thus formed is of non-direction or random oriented.
(B) Manufacture of artificial leather:
1. Impregnate the mat material prepared from (A) in foamable PVC plastic paste in a paste impregnating machine;
2. foam in a foaming machine;
3. slice into two sheets in a slicer;
4. roll.
1. Impregnate mat material of (A) in foamable PVC plastic paste in a paste impregnating machine;
2. draw from sheet machine non-foamable facing sheet and adhere to the paste impregnated mat;
3. print the surface in a printer,
4. foam and emboss in a foaming machine,
5. surface treatment in a treating machine;
6. grind the back in a grinder;
7. roll the product.
1. Impregnate the mat material of (A) in foamable PVC plastic paste in a paste impregnating machine;
2. foam in a foaming machine;
3. grind both surfaces in a grinder;
4. separately coat PU on a releasing paper in a coating machine, dry;
5. coat dual liquid type PU adhering agent in the coating machine;
6. adhere to the intermediate product from step 3 and dry on the coating machine;
7. curing or aging
8. release the paper on a releasing machine;
9. treat the surfaces in a treating machine;
10. roll.
First beat and mix the synthetic fiber staples then feed into a combing machine, set the fibers into lateral netting then into longitudinal netting by needle to foam non-woven mat.
Dip the non-woven mat of 2.0 m/m thickness in a paste impregnating machine, into 35 PHR foamable plastic paste, squeeze dry and press flat to form a mat of 2.3 m/m thick, containing 2.2 Kg/Yd.-38" plastic paste. Dry in a heating furnace of 10 m in length under 3 Yd./min. linear velocity, foam under 240° C. in a foaming machine, press to form a semi-finished product of 4.0 m/m thick, slice into two 2.0 m/m thick pieces. The final product is suitable for making shoe sole and luggage skeleton.
Dip non-woven mat of 1.5 m/m thickness in a paste impregnating machine, into 80-140 PHR foamable plastic paste, squeeze dry and press flat to form a mat of 2.0 m/m thick, containing 1.1 Kg/Yd.-38" plastic paste. Dry in heating furnace of 10 m in length, under 160° C. with a linear velocity of 3 Yd./min. Adhere in a sheet machine, under 175° C., to a PVC sheet of 0.25 m/m thickness drawn therefrom. Print the surface in a printer, foam under 220° C. in a foaming machine, emboss to form a semi-finished product of 3.0 m/m thick, treat the surfaces in a treating machine, grind the bottom surface with 120 mesh sand paper to acquire a thickness of 2.5 m/m. Inspect the product in an inspecting machine, cut to 20 Yd. length, roll and pack.
Dip the non-woven mat of 0.9 m/m thickness in a paste soaking machine, into a 80-140 PHR foamable plastic paste, squeeze dry and press flat to form a mat of 1.8 m/m thick, containing 1.2 Kg/Yd.-38" plastic paste. Dry in a heating furnace of 10 m in length, under 160° C. with a linear velocity of 3 Yd./min. Grind both surfaces with 120 mesh sand paper in a grinder to serve an intermediate product. Separately, in a coating machine coat PU resin on a releasing paper, dry under 130° C., apply a further coating of dual liquid type PU adherent, to promote the adhesion between PVC and PU surfaces. Adhere the ground intermediate product to PU coated paper, dry under 140° C., roll and deliver to curing or aging room, under 50° C. for 48 hours, tear away the releasing paper, treat the surface in a treating machine to improve the hand feel and brightness. Inspect, cut to 20 Yd. lengths, roll and pack.
In these embodiments the impregnated base mat is squeezed and pressed flat to retain 0.5-2.5 Kg/Yd.-38" of plastic paste and then dried at 140°-180° C. prior to further processing.
Claims (1)
1. The method of manufacturing an artificial leather which consists of preparing a base mat, impregnating the base mat with a paste of a first polymeric resin material which is a foamable PVC resin, to form a filled base mat, coating the filler base mat with a second polymeric resin material, wherein the filler base mat is squeezed and pressed flat to retain 0.50-2.5 Kg/Yd-38" of said paste, then dried at 140°-180° C., foamed and sliced to the desired thickness.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US06/555,706 US4614671A (en) | 1983-11-28 | 1983-11-28 | Artificial leather with non-woven or fluffy cloth base and foamed PVC filler |
JP61221730A JPS6375187A (en) | 1983-11-28 | 1986-09-19 | Plastic leather and its production |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US06/555,706 US4614671A (en) | 1983-11-28 | 1983-11-28 | Artificial leather with non-woven or fluffy cloth base and foamed PVC filler |
Publications (1)
Publication Number | Publication Date |
---|---|
US4614671A true US4614671A (en) | 1986-09-30 |
Family
ID=24218304
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US06/555,706 Expired - Fee Related US4614671A (en) | 1983-11-28 | 1983-11-28 | Artificial leather with non-woven or fluffy cloth base and foamed PVC filler |
Country Status (2)
Country | Link |
---|---|
US (1) | US4614671A (en) |
JP (1) | JPS6375187A (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5183695A (en) * | 1991-06-07 | 1993-02-02 | Kanegafuchi Kagaku Kogyo Kabushiki Kaisha | Interior finish surface material for automobiles |
US6383325B1 (en) * | 2000-05-10 | 2002-05-07 | Chai-Bang Tsai | Method for manufacturing a polyurethane product with high wetting ability, gas permeability and high water repellent ability by a dry transfer coating process |
CN103352376A (en) * | 2013-07-03 | 2013-10-16 | 六安三希皮革制品有限公司 | PVC synthetic leather for shoe vamps of high-grade sports shoes and production method thereof |
CN105544235A (en) * | 2015-12-02 | 2016-05-04 | 昆山阿基里斯人造皮有限公司 | Production method of polyvinyl chloride artificial leather |
US20170306138A1 (en) * | 2014-10-01 | 2017-10-26 | Sika Technology Ag | Manufacturing process and composition for foamed pvc-p rock shields |
US10933606B2 (en) * | 2015-06-16 | 2021-03-02 | Tmg—Tecidos Plastificados E Outros Revestimentos | Flexible composite material, method of obtention and uses thereof |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105463873B (en) * | 2015-12-22 | 2017-10-20 | 福建华夏合成革有限公司 | A kind of corrosion-resistant industrial artificial leather and preparation method thereof |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1168778A (en) * | 1965-10-21 | 1969-10-29 | Sumitomo Bakelite Co | Structural Foamed Products and Method for Production Thereof. |
US4349597A (en) * | 1980-07-07 | 1982-09-14 | Cleveland Plastics Of Tennessee, Inc. | Production of synthetic leather |
-
1983
- 1983-11-28 US US06/555,706 patent/US4614671A/en not_active Expired - Fee Related
-
1986
- 1986-09-19 JP JP61221730A patent/JPS6375187A/en active Pending
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1168778A (en) * | 1965-10-21 | 1969-10-29 | Sumitomo Bakelite Co | Structural Foamed Products and Method for Production Thereof. |
US4349597A (en) * | 1980-07-07 | 1982-09-14 | Cleveland Plastics Of Tennessee, Inc. | Production of synthetic leather |
Cited By (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5183695A (en) * | 1991-06-07 | 1993-02-02 | Kanegafuchi Kagaku Kogyo Kabushiki Kaisha | Interior finish surface material for automobiles |
US6383325B1 (en) * | 2000-05-10 | 2002-05-07 | Chai-Bang Tsai | Method for manufacturing a polyurethane product with high wetting ability, gas permeability and high water repellent ability by a dry transfer coating process |
CN103352376A (en) * | 2013-07-03 | 2013-10-16 | 六安三希皮革制品有限公司 | PVC synthetic leather for shoe vamps of high-grade sports shoes and production method thereof |
CN103352376B (en) * | 2013-07-03 | 2015-12-23 | 六安三希皮革制品有限公司 | Vamp PVC synthetic leather of high-grade sport footwear and preparation method thereof |
US20170306138A1 (en) * | 2014-10-01 | 2017-10-26 | Sika Technology Ag | Manufacturing process and composition for foamed pvc-p rock shields |
US10344157B2 (en) * | 2014-10-01 | 2019-07-09 | Sika Technology Ag | Manufacturing process and composition for foamed PVC-P rock shields |
US10465067B2 (en) | 2014-10-01 | 2019-11-05 | Sika Technology Ag | Manufacturing process and composition for foamed PVC-P rock shields |
US20200040172A1 (en) * | 2014-10-01 | 2020-02-06 | Sika Technology Ag | Manufacturing process and composition for foamed pvc-p rock shields |
US10920058B2 (en) * | 2014-10-01 | 2021-02-16 | Sika Technology Ag | Manufacturing process and composition for foamed PVC-p rock shields |
US10933606B2 (en) * | 2015-06-16 | 2021-03-02 | Tmg—Tecidos Plastificados E Outros Revestimentos | Flexible composite material, method of obtention and uses thereof |
CN105544235A (en) * | 2015-12-02 | 2016-05-04 | 昆山阿基里斯人造皮有限公司 | Production method of polyvinyl chloride artificial leather |
Also Published As
Publication number | Publication date |
---|---|
JPS6375187A (en) | 1988-04-05 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
REMI | Maintenance fee reminder mailed | ||
LAPS | Lapse for failure to pay maintenance fees | ||
STCH | Information on status: patent discontinuation |
Free format text: PATENT EXPIRED DUE TO NONPAYMENT OF MAINTENANCE FEES UNDER 37 CFR 1.362 |
|
FP | Lapsed due to failure to pay maintenance fee |
Effective date: 19900930 |